Biodegradable Polymer Manufacturing Costs Set To Fall

Biodegradable polymer producers are currently working toward reducing the cost of their manufacturing operations by increasing production capacity, improving process technology and utilizing low cost feedstocks, according to a recent study by SRI Consulting. Currently biodegradable polymers are much more costly than the commodity materials they are seeking to displace, which presents a significant barrier to widespread market acceptance.

The study found that two materials in particular offer the potential of lower prices: poly(lactic acid) (PLA) and newly developed aliphatic/aromatic copolyesters. Cargill Dow Polymers has announced that it will soon make a decision to invest in a large world-scale PLA production facility. Recently developed lactic acid production technology will enable low cost feedstock production. Both BASF and Eastman Chemical have developed biodegradable aliphatic/aromatic copolyesters. These new materials may be produced in existing polyester facilities.

SRIC also examined technology for producing starch-based polymers and polyhydroxybutyrate-valerate (PHBV). Starch-based polymers were the first of the second-generation biodegradable polymers commercialized in the early 1990s. PHBV is produced by Monsanto using bacterial fermentation.

First generation "biodegradable" polymers were commercialized in the 1980s. The public was dissatisfied with the incomplete degradation of these materials and in 1990 a class action lawsuit forced producers to remove the biodegradable claim. Subsequently, a second generation of biodegradable polymers was commercialized in the 1990s that may better meet not only the public's expectations but also improved scientific testing for biodegradability.

Worldwide biodegradable polymer consumption reached 31 million lb./year in 1996 and is projected to reach 150 million lb./year by 2001 according to this study. Most of this growth is expected in Europe where landfilling regulations, recycling fees and development of composting infrastructure is spurring the demand for biodegradable polymers. Loose-fill packaging and compost bags are currently the two major end uses for biodegradable polymers. Other uses that may grow in the future include food packaging, dishes and cutlery.

For further information on SRI Consulting's Process Economics Report 115C, Biodegradable Polymers, contact the report author, Gregory Bohlmann, 650-859-4128.